Life Fitness Weekly User manual

Activate Treadmill
Service Manual
REV August 16, 2021

Corporate Headquarters
10601 W Belmont Ave, Franklin Park, IL 60131 • U.S.A.
847.288.3300 • FAX: [phone]
Service phone number: 800.351.3737 (toll-free within U.S.A., Canada)
Global Website: www.lifefitness.com
International Offices
AMERICAS
North America
Life Fitness, LLC
10601 W Belmont Ave
Franklin Park, IL 60131 U.S.A.
Telephone: [phone]
Service Email:
customersupport@lifefitness.com
Sales/Marketing Email:
commercialsales@lifefitness.com
United Kingdom
Life Fitness UK LTD
Queen Adelaide
Ely, Cambs, CB7 4UB
Telephone: General Office (+44)
1353.666017
Customer Support (+44) 1353.665507
Service Email: uk.support@lifefitness.com
Sales/Marketing Email: life@lifefitness.com
All Other EMEA Countries and Distributor
Business EMEA*
Bijdorpplein 25-31
2992 LB Barendrecht
THE NETHERLANDS
Telephone: [phone]
Service Email:
EMEAServiceSupport@lifefitness.com
Brazil
Life Fitness Brasil
Av. Rebouças, 2315
Pinheiros
São Paulo, SP 05401-300
BRAZIL
SAC: 0800 773 8282 option 2
Telephone: [phone] option 2
Service Email: suportebr@lifefitness.com
Sales/Marketing Email:
vendasbr@lifefitness.com
Germany, Austria, and Switzerland
Life Fitness Europe GMBH
Neuhofweg 9
85716 Unterschleißheim
GERMANY
Telephone:
+49 (0) 89 / 31775166 Germany
+43 (0) 1 / 6157198 Austria
+41 (0) 848 / 000901 Switzerland
Service Email:
kundendienst@lifefitness.com
Sales/Marketing Email:
vertrieb@lifefitness.com
ASIA PACIFIC (AP)
Japan
Life Fitness Japan, Ltd
4-17-33 Minami Aoyama 1F/B1F
Minato-ku - Tokyo 107-0062
Japan
Telephone: [phone]
Fax: [phone]
Service Email: service.lfj@lifefitness.com
Sales/Marketing Email:
sales@lifefitnessjapan.com
Latin America and Caribbean*
Life Fitness, LLC
10601 W Belmont Ave
Franklin Park, IL 60131 U.S.A.
Telephone: [phone]
Service Email:
customersupport@lifefitness.com
Sales/Marketing Email:
commercialsales@lifefitness.com
Spain
Life Fitness IBERIA
C/Frederic Mompou 5,1º1ª
08960 Sant Just Desvern Barcelona
SPAIN
Telephone: [phone]
Service Email:
servicio.tecnico@lifefitness.com
Sales/Marketing Email:
info.iberia@lifefitness.com
Hong Kong
Life Fitness Asia Pacific LTD
32/F, Global Trade Square
21 Wong Chuk Hang Road
Hong Kong
Telephone: [phone]
Service Email: Service.HK@lifefitness.com
Sales/Marketing Email:
hongkong.sales@lifefitness.com
EUROPE, MIDDLE EAST, and AFRICA (EMEA)
Netherlands and Luxemburg
Life Fitness Atlantic BV
Bijdorpplein 25-31
2992 LB Barendrecht
THE NETHERLANDS
Telephone: [phone]
Service Email:
service.benelux@lifefitness.com
Sales/Marketing Email:
marketing.benelux@lifefitness.com
Belgium
Life Fitness Benelux NV
Parc Industrial de Petit-Rechain
4800 Verviers
BELGIUM
Telephone: [phone]
Service Email:
service.benelux@lifefitness.com
Sales/Marketing Email:
marketing.benelux@lifefitness.com
All Other Asia Pacific countries and distributor
business Asia Pacific*
32/F, Global Trade Square
21 Wong Chuk Hang Road
Hong Kong
Telephone: [phone]
Fax: [phone]
Service Email: Service.AP@lifefitness.com
Sales/Marketing Email:
Marketing.HK.Asia@lifefitness.com
*Also check www.lifefitness.com for local representation or distributor/dealer
Page 1 of 143

Table of Contents
Safety
Safety Instructions......................................................... 4
Immobilization Method................................................ 5
Introduction
Using this Manual.......................................................... 6
Customer Support Contact Information.....................6
Online References.........................................................6
Related Products........................................................... 6
Maintenance
Preventive Maintenance Schedule..............................7
Preventive Maintenance Tips.......................................7
Approved and Compatible Cleaners......................... 8
Theory of Operation
Drive Motor (DM)...........................................................9
Base Frame Electronics (BE)...................................... 10
Lift System (LS).............................................................15
Heart Rate System (HR)...............................................16
Stride System (SS)........................................................19
How To's
Knowledge Base..........................................................20
Adjust Lift Actuator..................................................... 20
Striding Belt Tracking and Tensioning..................... 21
Anti-Slip Pads...............................................................22
Bridge Weldment........................................................24
Console Replacement................................................ 30
Drive Motor.................................................................. 33
Drive Motor Belt.......................................................... 37
Emergency Stop..........................................................40
Ergo Bar........................................................................44
Front Roller...................................................................50
Heart Rate Sensors......................................................55
Home Switch................................................................ 57
IEC Receptacle.............................................................60
Leveler Assembly........................................................ 63
LifeSpring Absorbers..................................................64
Lift Frame......................................................................68
Lift Motor...................................................................... 72
Line Filter......................................................................75
Main Wire Harness...................................................... 78
Motor Controller Assembly........................................81
Motor Cover.................................................................84
On / Off Switch............................................................ 86
Polar Receiver.............................................................. 89
Rear Roller....................................................................92
Rear Roller Guards...................................................... 94
Striding Belt and Deck................................................95
Upper Bridge Cover................................................. 103
Uprights......................................................................108
Troubleshooting
Knowledge Base....................................................... 117
Troubleshooting the Treadmill............................... 117
Troubleshooting the Polar®Heart Rate Chest
Strap...................................................................... 118
System Level Troubleshooting................................120
Software
Refer to Console Service Manual............................134
Diagnostics
Refer to Console Service Manual............................135
Error code list
Refer to Console Service Manual............................136
Network Information
Refer to Console Service Manual............................137
Schematics
Schematic - Activate Treadmill................................138
LED Chart
Knowledge Base....................................................... 139
Motor Controller Functional Description...............139
Glossary
AC Current.................................................................140
Anti-Slip Pads.............................................................140
Cable Tie.................................................................... 140
Deck............................................................................140
DSP............................................................................. 140
DSP Motor Controller............................................... 140
EEPROM..................................................................... 140
E-Stop Switch.............................................................140
Front Roller................................................................ 140
Heart Rate Sensor / HR Sensor................................ 140
Idler Pulley Assembly............................................... 140
Jumper....................................................................... 140
LED..............................................................................140
Levelers...................................................................... 140
Lift Motor....................................................................140
Lifepulse™.................................................................. 140
LifeSpring®................................................................. 140
Main Drive Belt.......................................................... 140
PCB............................................................................. 140
Polar Receiver............................................................140
Rear Roller..................................................................140
Rear Roller Guards....................................................140
© Copyright 2021, Life Fitness, LLC. All Rights Reserved. Life Fitness, Hammer Strength, Cybex, ICG and SCIFIT are registered trademarks of
Life Fitness, LLC and its affiliated companies and subsidiaries. Brunswick and related trademarks used under license from Brunswick
Corporation. Disclaimer: Images and specifications are current as of the date of publication and are subject to change.
10601 W Belmont Ave, Franklin Park, IL 60131 • 847-288-3300
www.lifefitness.com • August 16, 2021 • 2021
Page 2 of 143

RPM.............................................................................141
Striding Belt............................................................... 141
Telemetry................................................................... 141
Telemetry Receiver................................................... 141
Warranty
What is Covered........................................................142
Who is Covered.........................................................142
How Long It is Covered............................................142
Who Pays Transportation and Insurance For
Service...................................................................142
What We Will Do To Correct Covered Defects.....142
What is Not Covered................................................ 142
What You Must Do....................................................142
How to Get Parts and Service.................................. 142
Exclusive Warranty....................................................142
Changes in Warranty Not Authorized.................... 143
Effects of State Laws................................................. 143
Warranty Information................................................143
© Copyright 2021, Life Fitness, LLC. All Rights Reserved. Life Fitness, Hammer Strength, Cybex, ICG and SCIFIT are registered trademarks of
Life Fitness, LLC and its affiliated companies and subsidiaries. Brunswick and related trademarks used under license from Brunswick
Corporation. Disclaimer: Images and specifications are current as of the date of publication and are subject to change.
10601 W Belmont Ave, Franklin Park, IL 60131 • 847-288-3300
www.lifefitness.com • August 16, 2021 • 2021
Page 3 of 143

1. Safety
Safety Instructions
Read all instructions before use.
CAUTION: Any changes or modifications to this equipment could void the product warranty.
CAUTION: Risk of injury to persons – to avoid injury, use extreme caution when stepping onto or off of a
moving belt. Read assembly instruction manual before using.
WARNING: Health-related injuries may result from incorrect or excessive use of exercise equipment. Life
Fitness Family of Brands STRONGLY recommends seeing a physician for a complete medical exam before
undertaking an exercise program, particularly if the user has a family history of high blood pressure or heart
disease, is over the age of 45, smokes, has high cholesterol, is obese, or has not exercised regularly in the past
year. If, at any time while exercising, the user experiences faintness, dizziness, pain, or shortness of breath, he or
she must stop immediately.
WARNING: To reduce the risk of burns, fire, electric shock, or injury, it is imperative to connect each product to
a properly grounded electrical outlet.
WARNING: Heart rate monitoring systems may be inaccurate. Over exercising may result in serious injury or
death. If you feel faint, stop exercising immediately.
WARNING: Do not use for stretching and do not attach straps or other devices.
WARNING: Keep batteries out of reach of children.
Some chest straps may contain a removable battery.
• Swallowing may lead to serious injury in as little as 2 hours or death, due to chemical burns and potential
perforation of the esophagus.
• If you suspect your child has swallowed a battery, immediately call your local poison control for fast, expert
advice.
• Examine devices and make sure the battery compartment is correctly secured, e.g. that the screw or other
mechanical fastener is tightened. Do not use if compartment is not secure.
• Dispose of used button batteries immediately and safely. Flat batteries can still be dangerous.
• Tell others about the risk associated with button batteries and how to keep their children safe.
WARNING: Keep the area 6.5 ft. (2 m) by 3 ft. (0.9 m) behind the treadmill clear of any obstructions, including
walls, furniture, and other equipment. Contact Customer Support Services for an optional longer power cord if
necessary.
WARNING: Be sure the emergency stop lanyard is clipped to the user and in proper position on the treadmill
before beginning any workout.
WARNING: The belt centering adjustment must be performed if the belt is not between the marks indicating
the maximum allowed lateral positions. Refer to Treadmill Assembly Instructions.
WARNING: This product can expose you to chemicals including Acrylonitrile, which is known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information go to http://
www.P65Warnings.ca.gov
DANGER: To reduce the risk of electrical shock or injury from moving parts, always unplug product before
cleaning or attempting any maintenance activity.
• Never operate the product if it has a damaged power cord or electrical plug, or if it has been dropped, damaged,
or even partially immersed in water. Contact Customer Support Services.
• Position the product so that the power cord plug to the wall is accessible to the user. Make sure that the power cord
is not knotted or twisted and that it is not trapped under any equipment or other objects.
• If the electrical supply cord is damaged, it must be replaced by the manufacturer, an authorized service agent, or a
similarly qualified person to avoid a hazard.
• Always follow the console instructions for proper operation.
• This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental
capabilities, or lack of experience or knowledge unless they have supervision or been given instruction concerning
the use of the appliance by a person responsible for their safety.
• Do not use this product outdoors, near swimming pools or in areas of high humidity.
• Never operate the product with the air openings blocked. Keep air openings free of lint, hair, or any other
obstructing material.
Page 4 of 143

• Never insert objects into any opening in these products. If an object should drop inside, turn off the power, unplug
the power cord from the outlet, and carefully retrieve it. If the item cannot be reached, contact Customer Support
Services.
• Never place liquids of any type directly on the unit, except in an accessory tray or holder. Containers with lids are
recommended.
• Do not use these products in bare feet. Always wear shoes. Wear shoes with rubber or high-traction soles. Do not
use shoes with heels, leather soles, cleats or spikes. Make sure no stones are embedded in the soles.
• Keep all loose clothing, shoelaces, and towels away from moving parts.
• Do not reach into, or underneath, the unit or tip it on its side during operation.
• This equipment is not intended for use by children. Keep children under the age of 14 away from the machine.
• Do not allow other people to interfere in any way with the user or equipment during a workout.
• Allow LCD consoles to “normalize” with respect to temperature for one hour before plugging the unit in and using.
• The product should never be left unattended when plugged in. Disconnect from the electrical outlet when not in
use, and before putting on or taking off parts. To disconnect, turn power OFF at the ON/OFF switch, then remove
plug from electrical outlet.
• Keep the power cord away from heated surfaces. Do not pull the equipment by the power cord or use the cord as a
handle. Do not run the power cord on the floor under or along the side of the treadmill.
• Handrails may be held to enhance stability as needed, but are not for continuous use.
• Never mount or dismount the treadmill while the running belt is moving. Use the handrails whenever additional
stability is required. In case of an emergency, such as tripping, grasp the handrails, and place the feet on the side
platforms.
• Never walk or jog backwards on the treadmill.
• Do not use this product in areas where aerosol spray products are being used or where oxygen is being
administered. Such substances create the danger of combustion and explosion.
• Use these products for their intended use as described in this manual. Do not use attachments that have not been
recommended by the manufacturer.
• In conformity with the European Union Machinery Directive 2006/42/EC, this equipment unloaded runs at sound
pressure levels below 70 dB (A) at the average operating speed of 12 km/hr (commercial units) and 8 km/hr (home
units). Noise emission under load is higher than without load.
• Free standing equipment shall be installed on a stable and leveled surface.
• Read all warnings on each product prior to starting a workout.
• If warnings are missing or damaged, please contact Customer Support Services immediately for replacement
warning labels. Warning labels are shipped with every product and should be installed before product is used. Life
Fitness Family of Brands is not responsible for missing or damaged warning labels.
Immobilization Method
The purpose of immobilizing the treadmill is to prevent unauthorized use. The system causes immobilization of the
treadmill when a pre-defined hard key sequence has been activated.
1. Set the display to read SELECT WORKOUT.
NOTE: Press the CLEAR key twice if not already there
2. Hold down the SPEED DOWN key and press the PAUSE key.
The treadmill now displays IMMOBILIZED. In this state, the treadmill cannot be operated. The belt and incline motors
are disabled. The treadmill will remain in this state across resets, power cycles, etc. To restore normal operation,
repeat the same key sequence; hold down the SPEED DOWN key, and press the PAUSE key. The treadmill will display
SELECT WORKOUT again.
Page 5 of 143

2. Introduction
Using this Manual
Descriptions using the words "left" and "right" refer to the orientation of a user using the product, facing the console.
"Front" is the area of the product with the console. The "Rear" of the product is behind the user.
Customer Support Contact Information
Refer to Corporate Headquarters for contact info.
To speed Customer Support Service’s response, please provide the following information to the customer support
technician:
• Serial number
• Model number
• Part name
• Part number
• Symptom of problem
Online References
Detailed Schematics are available online in Parts Manuals:
•https://www.lftechsupport.com access technical documentation and part manuals for Life Fitness, Hammer
Strength, and ICG.
•http://www.lifefitness.com/parts service parts ordering for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG
products along with warranty parts ordering and technician requests.
•https://lfworld.lifefitness.com easy to find Knowledge Base articles with answers to frequently asked questions and
product support documentation for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG.
Related Products
The Activate Treadmill uses the following console:
Activate console
Page 6 of 143

3. Maintenance
Preventive Maintenance Schedule
Item Weekly Monthly Biannually
Console Overlays Clean Inspect
Bottle Holders / Accessory
Trays
Clean Inspect
Console Mounting Bolts Inspect
Hardware Inspect
Frame Clean Inspect
Plastic Covers Clean Inspect
Lifepulse Sensors Clean / Inspect
Striding Belt Centered Inspect
Emergency Stop Magnet Clean / Inspect
Motor Cover Clean Vacuum / Clean
Motor Electronic
Compartment
Inspect
Drive Belt Inspect
Leg Levelers Inspect / Adjust
Front and Rear Rollers Inspect
Side Step Area Clean Inspect
Side Hand Rails Clean Inspect
Ergo™Front Handlebar Clean Inspect
Preventive Maintenance Tips
NOTE: Safety of the equipment can be maintained only if the equipment is examined regularly for damage or wear.
Keep the equipment out of use until defective parts are repaired or replaced. Pay special attention to parts that are
subject to wear, as outlined below.
The following preventive maintenance tips will keep the product operating at peak performance:
• Locate the product in a cool, dry place.
• Clean the display console and all exterior surfaces with an approved or compatible cleaner (see Approved and
Compatible Cleaners) and a microfiber cloth.
• Long fingernails may damage or scratch the surface of the console; use the pad of the finger to press the selection
buttons on the console.
• Check operation of the emergency stop system once a week.
• Inspect and vacuum the area directly surrounding and under the unit regularly.
• Vacuum around the striding belt regularly to keep debris from accumulating.
• Inspect exterior parts regularly for wear, particularly the striding belt, deck and line cord.
• Check to make sure the unit is properly leveled.
• Check the position (centering) of the striding belt.
NOTE: Normal belt operating position is for the belt to be located within the belt travel indicators on the rear roller
guards. Refer to Tracking (Centering) A Striding Belt or contact Customer Support Services for proper alignment
instructions.
Page 7 of 143

Approved and Compatible Cleaners
Two preferred cleaners have been approved by reliability experts: PureGreen 24 and Gym Wipes. Both cleaners will
safely and effectively remove dirt, grime and sweat from equipment. PureGreen 24 and the Antibacterial Force
formula of Gym Wipes are both disinfectants that are effective against MRSA and H1N1.
PureGreen 24 is available in a spray which is convenient for gym staff to use. Apply the spray to a microfiber cloth and
wipe down the equipment. Use PureGreen 24 on the equipment for at least 2 minutes for general disinfection
purposes and at least 10 minutes for fungus and viral control.
Gym Wipes are large, durable pre-moistened wipes to use on the equipment before and after workouts. Use Gym
Wipes on the equipment for at least 2 minutes for general disinfection purposes.
Contact Customer Support Services to order these cleaners (1-800-351-3737 or email:
customersupport@lifefitness.com).
Mild soap and water or a mild non-abrasive household cleaner can also be used to clean the display and all exterior
surfaces. Use a soft microfiber cloth only. Apply the cleaner to the microfiber cloth before cleaning. DO NOT use
ammonia or acid based cleaners. DO NOT use abrasive cleaners. DO NOT use paper towels. DO NOT apply cleaners
directly to the equipment surfaces.
Page 8 of 143

4. Theory of Operation
Drive Motor (DM)
Overview:
The drive motor is a three-phase alternating current (AC) motor driven off of a 300-volt bus supplied by the motor
controller.
The motor converts electrical energy to mechanical energy.
The mechanical energy is transferred to the main roller by means of a drive belt. The drive belt couples the motor
pulley with the front roller pulley. It is tensioned by a spring-loaded tensioner.
The motor is equipped with the thermal cut-off switch. Should the motor start to overheat the switch will open to
prevent heat-related damage to the motor components.
Page 9 of 143

Base Frame Electronics (BE)
Item Description Qty.
1 Drive motor 1
2 Power cord outlet 1
3 Coax cable connector 1
4 Power switch 1
5 Line filter 1
6 Digital Signal Processor (DSP) 1
7 Lift motor 1
8 Limit switch 1
Overview:
The electronics in the Activate Series Treadmill controls the drive motor, lift motor and provides voltage and
communication to the console. Circuitry is contained on the motor controller which consists of a PCB, heat sink and
bracket assembly. There are two versions of the motor controller; the 100-120 VAC and 220-230 VAC.
Input Power:
The treadmill is powered by a detachable AC line cord which is included and plugs into the IEC connector.
When the AC line cord is plugged into an outlet, the power goes through an On / Off switch and applied to the input
of a line filter. Also on the input of the line filter are transient protectors. The transient protectors are connected to
ground through a wire that has a jumper in it. The treadmill is delivered with the jumper connected and which can be
removed for test purposes. The output of the line filter connects to the motor controller board. To prevent the wrong
power form being applied, the 100-120 VAC motor controller has a three position plug and the 220-240 VAC motor
controller has a two position plug.
Page 10 of 143

Motor Controller:
AC voltage is supplied to the motor controller where it is rectified to DC. On 120 volt units the rectified DC is doubled
to 320 volts. On 230 volt units it is just filtered. This circuit is protected from inrush current by a current limiter. The
current limiter has normally open relay contacts connected across it and is only needed on start-up.
When power is applied to the motor controller the power relay turns on after a short delay current limiter relay closes
thus removing the current limiter from the circuit. The current limiter is only needed on power up. This results in two
distinct relay clicks being heard when powering up the treadmill.
The DC voltage is converted back to three phase 300 volts AC, then applied to the motor. The conversion circuit also
produces the speed and phase control pulses. As a safety the motor has a temperature switch that will open when the
temperature is exceeded removing the power from the motor.
Lift Control:
The lift motor is powered from the motor control board. The buttons on the console control the level and direction of
the lift motor. The home switch on the treadmill frame gives a reference to the console so it can dive the lift motor with
the proper signal attain the desired incline. All incline levels are achieved by a running the lift motor a calculated time.
Also that is why the treadmill must find home position before running a work out.
Non-Decline Units
Home Switch = Closed
NOTE: The transition from OPEN to CLOSED indicates that the treadmill reached its maximum decline.
The table below describes the behavior of the Activate Home switch.
NOTE: The system automatically configures itself as an non-decline or a decline-capable unit. This is accomplished by
recognizing the wiring of the Home switches.
% Incline Home switch
+15.0 Not activated
15.0 Not activated
1.0 Not activated
0.5 Not activated
0.0 Activated
-0.5 n/a
-3.0 n/a
-4.0 n/a
Activated = switch depressed
The on-time of the Lift Motor is controlled to provide the commanded incline. A frequency detect circuit on the motor
controller detects whether the input AC line frequency is 50 Hz or 60 Hz and adjusts the on time to obtain the correct
incline.
Power Supply:
The motor controller contains a fly-back power supply that powers the console circuitry as well as all circuitry on the
motor controller. The fly-back power supply provides 6 VDC and 12 VDC to the console. These voltages are isolated
from the AC line voltage. The same fly-back supply also provides supply voltages to the rest of the motor controller.
These voltages are not isolated from AC line but are referenced to the motor controller bus voltage. The power supply
is a universal input supply and will operate from 85 VAC to 264 VAC.
Page 11 of 143

Console Interface:
The motor controller communicates to the console processor via a single wire serial communications.
NOTE: JW3 should be present for Activate treadmills. Other treadmills which use two wire communication will have
JW3 on the motor controller.
Opto-isolators are provided on the motor controller to isolate the transmit line and receive line since the ground
reference for the motor controller circuitry is not the same as that of the console. Motor controller software updates
can be performed by using it’s built in field re-programmability capability directly or via the console CSAFE interface.
An additional optically isolated signal the DSP controller receives from the console is the Emergency Stop Signal which
controls the input power relay.
Motor Controller Software:
The motor controller uses proprietary control algorithms to control the ac induction motor to allow for maximum
efficiency, noise control and smoothness over the full range of operation.
Onboard sensors monitor bus voltage, motor current and power module temperature ensuring component limits are
not exceeded.
Line voltage compensation allows wide voltage fluctuations to be transparent to the exerciser.
Maximum average power is regulated allowing short term peaks while still controlling average power.
Motor Controller diagnostics keep track of 34 parameters and maximums to aid in appraising the health and
performance of the system. These combined with indicator LED’s help the service technician diagnosing and
correcting any system issues.
Indicators and Displays
There are ten LED’s on the 92343.
LED
number
Description LED
number
Description
1 12V indicator 6 V bus indicator
2 6V indicator 7 +Vd indicator
3 Tx Communication indicator 8 3.3V indicator
4 Lift (Up) direction 9 Incline Home position indicator
5 Lift ON 10 Incline Bottom position indicator
NOTE: LED 9 and LED 10 are connected in parallel
Connectors
P1 - six position female Mate-N-Lock connector for motor.
Pin number Description
P1-1 Frame
P1-2 Phase W
P1-3 Phase V
P1-4 Phase U
P1-5 Not Used
P1-6 Not Used
P4 - four position Micro-ft connector for limit switches.
Pin number Description
P4-1 Zero Position Switch
Page 12 of 143

Pin number Description
P4-2 Zero Position Switch return (GND)
P4-3 Bottom Limit Switch
P4-4 Bottom Limit Switch return (GND)
P5 - ten position Mini-ft jr. for console power and signals.
Pin number Description
P5-1 GND
P5-2 no connection
P5-3 6 VDC (Activate)
P5-4 6 VDC (Activate)
P5-5 no connection
P5-6 RXD
P5-7 TXD
P5-8 no connection
P5-9 12 VDC
P5-10 ESS
P6 - four position Mate-N-Lock connector for lift actuator.
Pin number Description
P6-1 Down
P6-2 Hot
P6-3 Up
P6-4 no connection
P7 - three position Mini-ft for 120VAC and for input power 2 pos for 230V.
Pin number Description
P7-1 Line
P7-2 Neutral
P7-3 Not Used
P8 - two position Mini-ft Jr. for motor thermal switch.
Pin number Description
P8-1 Therm1
P8-2 Therm2
P10 - three position C-grid connector for future expansion.
Pin number Description
P10-1 TBD
P10-2 TBD
Page 13 of 143

Pin number Description
P10-3 TBD
Page 14 of 143

Lift System (LS)
Overview:
The Lift Motor System is comprised of the Lift Motor, the Lift Frame and the the Home Switch.
NOTE: For details on the utilization of switches see Base Frame Electronics (BE).
In order for the lift system to be operational, the Emergency Stop Switch located on the console area must be properly
engaged. The Lift Motor is pinned to the Lift Motor Support Bracket on the treadmill frame on one end and is pinned
on the other end to the Lift Frame. The Lift Frame is also pinned to the treadmill frame.
The Lift Motor consists of a gear box, a steel ACME screw and a steel tube. The steel tube has an engineered plastic
nut that is fixed on one end of the tube. The ACME screw is pinned to the output gear on the gear box on one end and
screws into the nut on the steel tube on the other end. As the ACME screw rotates the steel tube extends or retracts
which raises or lowers the treadmill. There are internal limit switches on the gearbox to prevent over-travel.
The Lift Motor is programmed to incline the treadmill in 0.5% increments. The desired incline is commanded through
the incline up or down arrows or through the keypad on the console. When a user first starts the treadmill the Lift
Motor will lower the treadmill until the Home Switch is activated (this is 0% incline or level) unless the treadmill is
already at 0% incline. If the Home Switch cannot be activated, the console will display a message after a given
duration, stating incline inoperative continue if desired.
One way of determining if a Lift Motor or a Home Switch and/or the cable leading to it is electrically defective is by
observing whether or not certain LED’s on the motor controller light up. Similarly, knowing that both the Lift Motor and
the Home Switch are electrically good and the LED’s do light up but the treadmill is not able to be inclined or lowered
may be an indication that the Lift Motor is mechanically defective or the controller is bad. Electrical troubleshooting of
base electronics is described in Base Frame Electronics.
Page 15 of 143

Heart Rate System (HR)
Polar®Telemetry Receiver:
The Polar Telemetry receiver used in this generation of product is the CODED telemetry receiver.
A coded telemetry receiver has the following characteristics:
• The maximum range of the transmitter is three feet (one meter).
• The initial range of the transmitter is one foot (0.3 meter).
• To establish a connection, user must stand within one foot of the receiver. It may take up to one minute to establish
successful coded communication.
• This receiver works fine with the non-coded telemetry chest strap.
• The in-chest strap battery may not be replaceable. For troubleshooting use a telemetry simulator sold by Polar.
• It is not immune to EMI - the previous version was not either.
• It does not guarantee complete protection against cross-talk, but only minimizes the chances of it happening.
NOTE: The telemetry receiver is mounted in the console bezel.
The in-console coded Polar receiver works best with the coded telemetry straps (although non coded straps are
supported as well).
The coded chest strap, after establishing a code with the telemetry receiver, sends out user's heart rate in a form of a
pulse. A non-coded chest strap sends user's heart rate in a similar fashion.
The performance of the telemetry heart rate system is dependent upon a number of factors:
• Conductivity of the signal from user's chest to the telemetry chest strap (sensors must be clean, moist, user's skin
and electrical properties must foster electrical signal conductivity).
• The condition of the chest strap battery must be good (often there is no method to check it, since this battery is not
replaceable).
• The condition of the chest strap electrodes (they must not be broken).
• Electromagnetic Interference (usual EMI suspects are: fluorescent lighting, high power lines, home appliances,
personal electronics).
• Proper grounding of the product at the power outlet.
• Proper orientation of the Polar receiver: longer side MUST be parallel to the floor.
• Proper mounting of the Polar receiver in the product. If it falls off, it will change the antenna orientation.
IMPORTANT: You must be properly grounded with an ESD strap when replacing the Polar telemetry board.
Lifepulse™Theory of Operation
The Lifepulse contact heart rate system is designed to sense the electrical signals originating from the heart as it beats
and, using software, compute and display the corresponding heart rate value on the console readout. The two pairs of
electrodes on the Treadmill Ergo bar (left and right) are the point of contact at which these signals are picked up and
transmitted from the body to the Lifepulse circuitry. A hands-on detect circuit monitors for a change in voltage
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corresponding to the input for each of the left and right sensor pairs to determine if either or both are being held.
Both sensors must be held in order for the electrical signal from the heart to be measured. This is similar to measuring
the voltage of a battery with a voltmeter. In order to measure a battery the voltmeter must be connected across the
battery terminals (one lead to the positive and one lead to the negative). Similarly, the heart can be thought of as a
voltage source or battery and in order to measure it’s voltage you must measure across its terminals. Essentially, when
the left and right sensors are held they act like the leads of the voltmeter. Since an electrical path exists from the
electrodes held in one hand, up the arm, across the body (and the heart), down the other arm and into the other hand
holding the other pair of electrodes, a voltage can be measured. This is how the Lifepulse signal is measured. And just
like measuring a battery, the polarity of the voltage is important so the left and right electrodes must correspond to the
left and right user hands.
To pick up the heart signal Lifepulse must use a very sensitive high gain differential amplifier. This is primarily due to
the signal’s initial low amplitude as it originates from the heart (typically less than 2 millivolts peak to peak) and the
resultant attenuation, or signal drop, as it travels through the body and into the electrodes. This type of amplifier is
different from a regular amplifier in that only the differences between the inputs are amplified. In this way common
signals, typically electrical noise, appearing on both inputs can be simultaneously ignored while the differences are
amplified.
The output of this high gain differential amplifier, when neither or only one electrode pair is held, is meaningless
because the inputs to the amplifier basically act as antenna picking up and amplifying stray electrical signals from the
environment. Ideally, once both electrode pairs are held, as detected by the hands-on circuitry, the heart signal can be
isolated, amplified and presented to the software for analysis. In practice however, additional unwanted signals exist.
Some of these signals come from other muscles which lay along the “voltage” path to the heart being measured (such
as arm and chest muscles). Similarly, hand to electrode contact problems which tend to weaken the signal or even
introduce new signals which hide the actual heart signal can occur. The Lifepulse software attempts to isolate just the
heart signal from all other unwanted signals and noise using complex software techniques.
Basically, the Lifepulse software samples the amplified signal picked up at the electrodes many times a second looking
for the heart pulses. Depending upon the amount of noise, size of signal and/or irregularity of the heart pulse, it may
take many seconds (from 4 to 20 or more) to confidently determine a value. And if a value cannot be confidently
determined, a heart rate will not be displayed. To increase the detection of a heart signal, the Lifepulse software
attempts to expand the sampled signal to maximize the important features. A Gain value which represents the relative
amount the signal was expanded is displayed in the Lifepulse diagnostic screen and can range from 1 to 99. An
assessment of the strength of the signal can be directly related to this gain value.
Input signals already at maximum levels require a low gain because their features cannot be further expanded without
losing information. Very weak signals require more gain thus expanding them to full scale so their features can be
easily picked out. This scaling is done dynamically over consecutive blocks of samples with each gain computed
relative to the highest signal component within that block. The strength of the signal determines the effectiveness of
the scaling.
In general, weak signals are less desirable than strong ones and very strong signals are less desirable than weaker
ones. Obviously, weak signals requiring high gain values means that the weak heart pulses will be competing with
other low level background noise when both are scaled up making it hard to determine the heart signal from the
background signals. On the other hand, strong signals, usually not from the heart pulse itself, will ultimately limit the
amount of scaling that can be applied. Typical gain values for low noise signals which produce good LifePulse® heart
rates are generally between 10 and 30. Above 30 means the heart signal is weaker and below 10 means other noise
signals are too strong thus overpowering the heart pulses. Just as the gain value indicates the strength of the heart
signal the Confidence number indicates the quality of the heart rate reading when one is displayed.
The Lifepulse software uses many methods to analyze the heart signal and zero in on the heart rate reading. The
Confidence number which is also displayed in the Lifepulse diagnostic display indicates the agreement in the
computed heart rate number among these different methods and therefore the confidence the heart rate displayed is
correct. This is important when Cardio workouts, which change the load based on the difference between the current
and target heart rates, are used. If a confident heart rate cannot be determined Cardio workout programs cannot
automatically adjust the load to reach the target heart rate. Confidence values can range from 0 to 9 with 0 being the
least confident reading and 9 being the most confident. Cardio program load changes occur when heart rate readings
have confidence values of 5 or higher.
Some factors which affect Lifepulse's ability to determine a heart rate:
Hand slip and / or
grip pressure
changes on
electrodes:
This can produce noise spikes which drives up gain values and lowers the ability to detect the
features of the actual heart pulses.
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Dry and / or calloused
hands:
This can further reduce the already low amplitude heart signal picked up from the hands by
the electrodes.
Dirty and / or
contaminated hands:
This can also reduce the signal being measured.
Amount of upper
body movement:
This can add signals which must be evaluated and filtered out in the software. Sometimes
these signals can be regular enough to look like heart pulses.
Individual’s own
heart pulse
amplitude:
Other noise signals compete with the low heart signals.
Irregular heart
rhythms:
Missing, skipped or irregular heart beats require longer sample times to compute.
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